U.S. patent application number 12/784850 was filed with the patent office on 2010-12-23 for process for producing polycarbonate.
This patent application is currently assigned to Bayer MaterialsScience AG. Invention is credited to Andreas Bulan, Pieter Ooms, Johann Rechner, Michael Traving, Rainer Weber.
Application Number | 20100324256 12/784850 |
Document ID | / |
Family ID | 43049198 |
Filed Date | 2010-12-23 |
United States Patent
Application |
20100324256 |
Kind Code |
A1 |
Ooms; Pieter ; et
al. |
December 23, 2010 |
PROCESS FOR PRODUCING POLYCARBONATE
Abstract
A process is described for producing polycarbonate and utilizing
at least some of the process waste water by concentrating the
sodium chloride-containing waste water phases for the electrolysis
using osmotic membrane distillation, if appropriate with
simultaneous dilution of the sodium hydroxide solution obtained
from the electrolysis for the polycarbonate production process.
Inventors: |
Ooms; Pieter; (Krefeld,
DE) ; Bulan; Andreas; (Langenfeld, DE) ;
Weber; Rainer; (Odenthal, DE) ; Rechner; Johann;
(Kempen, DE) ; Traving; Michael; (Burscheid,
DE) |
Correspondence
Address: |
CONNOLLY BOVE LODGE & HUTZ, LLP
P O BOX 2207
WILMINGTON
DE
19899
US
|
Assignee: |
Bayer MaterialsScience AG
Leverkusen
DE
|
Family ID: |
43049198 |
Appl. No.: |
12/784850 |
Filed: |
May 21, 2010 |
Current U.S.
Class: |
528/200 |
Current CPC
Class: |
C01D 3/04 20130101; B01D
61/364 20130101; B01D 2311/14 20130101; C08G 64/24 20130101 |
Class at
Publication: |
528/200 |
International
Class: |
C08G 64/04 20060101
C08G064/04 |
Foreign Application Data
Date |
Code |
Application Number |
Jun 4, 2009 |
DE |
102009023940.5 |
Claims
1. A process for producing polycarbonate comprising: a) producing
phosgene by reacting chlorine with carbon monoxide; b) reacting the
phosgene formed in step a) with at least one bisphenol in the
presence of an aqueous alkali metal containing base to form a
polycarbonate and an alkali metal chloride-containing reaction
waste water solution; c) separating off and working up the
polycarbonate formed in step b) from the alkali metal
chloride-containing reaction waste water solution; e) distilling at
least a portion of the alkali metal chloride-containing reaction
waste water solution remaining after step c) via osmotic membrane
distillation to obtain an enriched alkali metal chloride-containing
solution; f) electrochemically oxidating of at least a portion of
the alkali metal chloride-containing solution from e) to obtain
chlorine, an alkali metal hydroxide solution and, optionally,
hydrogen.
2. The process of claim 1, further comprising, in a step d),
separating solvent residues and, optionally, catalyst residues (d1)
from the alkali metal chloride-containing reaction waste water
solution remaining after step c) and subsequently feeding the
resulting solution to the osmotic membrane distillation in step
e).
3. The process of claim 2, wherein step d) is achieved by
extracting or stripping the alkali metal chloride-containing
reaction waste water solution with steam and/or subsequently
treating the alkali metal chloride-containing reaction waste water
solution with an adsorbent (d2).
4. The process of claim 3, wherein the adsorbent (d2) in activated
charcoal.
5. The process of claim 2, wherein the osmotic membrane
distillation in step e) uses an alkali metal hydroxide solution as
a water acceptor.
6. The process of claim 1, wherein the osmotic membrane
distillation in step e) is operated at a temperature in the range
of from 10 to 100.degree. C.
7. The process of claim 6, wherein the osmotic membrane
distillation in step e) is operated at a temperature in the range
of from 20 to 50.degree. C.
8. The process of claim 1, wherein the osmotic membrane
distillation in step e) is operated at an absolute pressure in the
range of from 1.0 to 1.4 bar
9. The process of claim 1, wherein the osmotic membrane
distillation in step e) is operated at an absolute pressure in the
range of from 1.1 to 1.2 bar.
10. The process of claim 1, wherein the osmotic membrane
distillation in step e) is operated at a differential pressure in
the range of from 20 to 150 bar.
11. The process of claim 1, wherein the osmotic membrane
distillation in step e) is operated at a differential pressure in
the range of from 30 to 100 bar.
12. The process of claim 1, wherein the osmotic membrane
distillation in step e) uses an an Accurel PP membrane.
13. The process of claim 1, wherein at least a portion of the
alkali metal chloride-containing solution obtained in step e) is
added to the brine circuit of a membrane electrolysis for producing
chlorine, sodium hydroxide solution and, optionally, hydrogen.
14. The process of claim 1, wherein additional alkali metal
chloride for increasing the alkali metal chloride concentration is
added to the alkali metal chloride-containing solution in the
electrolysis in step f).
15. The process of claim 2, wherein, in d1), before treatment with
an absorbent (d2), the pH of the alkali metal chloride-containing
reaction waste water solution remaining after the separation in
step c) is set to below 8.
16. The process of claim 1, wherein the at least one bisphenol is
of the general formula HO--Z--OH wherein Z is an aromatic moiety
having from 6 to 45 carbon atoms, wherein said aromatic moiety
optionally contains one or more aromatic rings, is optionally
substituted, and optionally contains aliphatic moieties or
cycloaliphatic moieties or heteroatoms as bridging units.
17. The process of claim 1, wherein the at least one bisphenol is
selected from the group consisting of hydroquinone, resorcinol,
dihydroxybiphenyls, bis(hydroxyphenyl)alkanes,
bis(hydroxyphenyl)cycloalkanes, bis(hydroxyphenyl)sulphides,
bis(hydroxyphenyl)ethers, bis(hydroxyphenyl)ketones,
bis(hydroxyphenyl)sulphones, bis(hydroxyphenyl)sulphoxides,
.alpha.,.alpha.'-bis(hydroxyphenyl)diisopropylbenzenes,
bis(hydroxyphenyl)phthalimidines, and alkylated, ring-alkylated,
and ring-halogenated compounds thereof.
18. The process of claim 1, wherein the at least one bisphenol is
selected from the group consisting of 4,4'-dihydroxydiphenyl,
2,2-bis(4-hydroxyphenyl)-1-phenylpropane,
1,1-bis(4-hydroxyphenyl)phenylethane,
2,2-bis(4-hydroxy-phenyl)propane,
2,4-bis(4-hydroxyphenyl)-2-methylbutane,
1,3-bis[2-(4-hydroxyphenyl)-2-propyl]benzene,
2,2-bis(3-methyl-4-hydroxyphenyl)propane,
bis(3,5-dimethyl-4-hydroxyphenyemethane,
2,2-bis(3,5-dimethyl-4-hydroxyphenyl)propane,
bis(3,5-dimethyl-4-hydroxyphenyl)sulphone,
2,4-bis(3,5-dimethyl-4-hydroxyphenyl)-2-methylbutane,
1,3-bis[2-(3,5-dimethyl-4-hydroxyphenyl)-2-propyl]benzene,
2-hydrocarbyl-3,3-bis(4-hydroxyphenyl)-phthalimidine,
3,3-bis(4-hydroxyphenyl)-1-phenyl-1H-indol-2-one,
2,2-bis(4-hydroxyphenyl)-1-phenyl-1H-indol-2-one,
3,3-bis(4-hydroxyphenyl)-1-methyl-1H-indol-2-one,
2,2-bis(4-hydroxyphenyl)-1-methyl-1H-indol-2-one,
3,3-bis(4-hydroxyphenyl)-N-methylphthalimidine,
3,3-bis(4-hydroxyphenyl)-N-phenyl-phthalimidine, and
1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane.
19. The process of claim 1, wherein step c) comprises at least the
following substeps: cc) separating an organic phase comprising the
polycarbonate-formed in step b) from the alkali metal
chloride-containing reaction waste water solution; and dd) washing
the organic phase obtained in step aa) at least once; wherein at
least a portion of the wash phase(s) from bb), optionally after
separation of catalyst residues and/or organic solvent residues, is
used as a partial substitute of the water for producing the aqueous
alkali metal hydroxide solution for use in step b).
20. The process of claim 1, wherein the alkali metal of the alkali
metal chloride of the alkali metal chloride-containing reaction
waste water solution is sodium.
Description
RELATED APPLICATIONS
[0001] This application claims benefit to German Patent Application
No. 10 2009 023 940.5, filed Jun. 4, 2009, which is incorporated
herein by reference in its entirety for all useful purposes.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a process for producing
polycarbonate, wherein concentration of sodium-chloride-containing
process waste water from the polycarbonate phase boundary process
is increased by osmotic distillation.
[0003] Polycarbonates are customarily produced by a continuous
process, by producing phosgene and subsequent reaction of
bisphenols and phosgene in the presence of alkali metal and a
nitrogen catalyst, chain stoppers and optionally branching agents
in a mixture of aqueous-alkaline phase and an organic solvent in
the boundary phase.
##STR00001##
[0004] The production of polycarbonates, e.g. by the phase boundary
process, is described in principle in the literature, see, e.g. in
Chemistry and Physics of Polycarbonates, Polymer Reviews, H.
Schnell, Vol. 9, John Wiley and Sons, Inc. (1964), pp. 50/51.
[0005] In the production of polycarbonates, the two-phase boundary
process has been proven for many years. The process makes possible
the production of thermoplastic polycarbonates in a number of
fields of use such as, e.g. data carriers (CD, DVD), for optical
applications or for medical applications.
[0006] Frequently, quality features which are described as
important for the polycarbonate are good thermal stability and low
yellowing. Less attention has been paid to date to the quality of
the waste water occurring in the production of polycarbonates. In
particular, pollution of the waste water with residual organics
such as, e.g. residual phenols, is of importance here for any
further treatment of the waste water, e.g. by a sewage treatment
plant or by ozonolysis for oxidation of the residual organics. Here
there have been a number of applications in which, however,
predominantly methods for subsequent waste water treatment are
described with the purpose of reducing the pollution by phenolic
components as described, e.g., in JP 08 245 780 A, DE 19 510 063
A1, JP 03 292 340 A, JP 03 292 341 A and JP 02 147 628 A.
[0007] The pollution of the waste water with residual organics such
as, e.g. with bisphenols or phenols, can be kept low by working
with a high phosgene excess. However, this is undesirable for
economic reasons.
[0008] In the production of polycarbonates with a reduced phosgene
excess, there is the risk that not all of the bisphenol or all of
the monophenol reacts to completion, passes into the waste water
and pollutes the waste water. In addition there is the risk that
the phase separation and the washing is made more difficult because
surface-active phenolic OH groups remain in the polymer. As a
result, not all of the water-soluble impurities may be extracted
from the organic phase. This can in turn adversely affect the
product quality.
[0009] It must still be emphasized that the production of
polycarbonate of high quality by a continuous two-phase boundary
process with simultaneously low pollution of the waste water
according to the prior art is only possible with high phosgene
excess or with phase separation problems associated with quality
losses of the polycarbonate or by subsequent treatment of the waste
water, as a result of which the economic efficiency of the process
is reduced.
[0010] However, in these known processes, a high residual phenol
value in the waste water of these processes, which can pollute the
environment and can lead to an enhanced waste water problem for the
sewage treatment plants, requires complex purification operations.
For instance WO 03/070639 A1 describes removal of the organic
impurities in the waste water by extracting with methylene
chloride.
[0011] Customarily the sodium-chloride-containing solution is freed
from solvents and organic residues and is then disposed of.
[0012] It is also known that the sodium-chloride-containing waste
waters can be purified according to EP 1 200 359 A1 or U.S. Pat.
No. 6,340,736 A by ozonolysis and said waste waters can then be
used in sodium chloride electrolysis. A disadvantage of this
process is the very costly ozonolysis.
[0013] According to EP 541 114 A2, a sodium chloride-containing
waste water stream is concentrated by evaporation up to complete
removal of the water and the remaining salt together with the
organic impurities is subjected to a thermal treatment, as a result
of which the organic components are decomposed. Particular
preference is given to the use of infrared radiation. A
disadvantage of the process is that the water must be completely
evaporated, and so the process cannot be carried out
economically.
[0014] According to WO 03/070639, the waste water from production
of polycarbonate is purified by extraction and then supplied to the
sodium chloride electrolysis. However, only a maximum 14% by weight
of the sodium chloride from the waste water of the polycarbonate
production can be recycled into the NaCl electrolysis, since in the
case of larger amounts of NaCl-containing waste water, the water
introduced into the electrolysis together with the NaCl-containing
waste water would bring the water balance of the sodium chloride
electrolysis out of equilibrium.
[0015] The sodium chloride-containing solutions which occur in the
production of polycarbonate typically have a sodium chloride
content of 6 to 10% by weight. Therefore, all of the sodium
chloride present in the solutions cannot ever be recycled to
chloride and sodium hydroxide solution in the NaCl electrolysis. At
a sodium chloride concentration of 10% by weight, in the standard
sodium chloride electrolysis using a commercially conventional
ion-exchange membrane which exhibits water transport of 3.5 mol of
water per mol of sodium, only the use of approximately 13% of the
sodium chloride from the sodium chloride-containing solutions
succeeds. Increase of concentration up to a saturated sodium
chloride solution of approximately 25% by weight would yield a
recycling rate of 38% of the sodium chloride present in the sodium
chloride-containing solution. Complete recycling of the sodium
chloride-containing solution is currently unknown.
[0016] Processes for raising concentration by removing water from
the alkali-metal-chloride-containing waste water are known.
[0017] According to WO 01/38419, concentration of the sodium
chloride-containing solution is increased by evaporation by means
of a thermal process, in such a manner that a highly concentrated
sodium chloride solution can be fed to the electrolysis cell.
However, the evaporation is energy-intensive and costly.
[0018] Also, for example, reverse osmosis or, particularly
preferably, membrane distillation or membrane contactors can be
used (see MELIN; RAUTENBACH, Membranverfahren [Membrane processes];
SPRINGER, BERLIN, 2003). A disadvantage in this case is the high
energy requirement to overcome the high osmotic pressures, as a
result of which the process is no longer economically
efficient.
[0019] The above integrated processes all have the disadvantage
that, in combination with polycarbonate production only, NaCl
solutions with a limited concentration (6-10% by weight) are fed to
the electrolysis, and so reutilization of NaCl is only possible to
a restricted extent or the concentration is energy-intensive and
expensive.
[0020] Proceeding from the above-described prior art, the object is
to provide a polycarbonate production process in which, during the
recycling of the waste water, the reaction of sodium chloride to
form chlorine and sodium hydroxide solution and possibly hydrogen
can proceed with minimum energy use and therefore in a particularly
economic and resource-saving manner. In addition, a process should
be provided which yields products in high purity and good yield and
makes possible a reduction of the environmental pollution and/or
the waste water problems in sewage treatment works.
[0021] The object is achieved in that, in the process, sodium
chloride-containing waste water phases are utilized by an upstream
increase of concentration using an osmotic membrane distillation of
the NaCl solution from the polycarbonate production for the
electrolysis.
EMBODIMENTS OF THE INVENTION
[0022] An embodiment of the present invention is a process for
producing polycarbonate comprising: [0023] a) producing phosgene by
reacting chlorine with carbon monoxide; [0024] b) reacting the
phosgene formed in step a) with at least one bisphenol in the
presence of an aqueous alkali-metal-containing base to form a
polycarbonate and an alkali-metal-chloride-containing reaction
waste water solution; [0025] c) separating off and working up the
polycarbonate formed in step b) from the alkali metal
chloride-containing reaction waste water solution; [0026] e)
distilling at least a portion of the alkali metal
chloride-containing reaction waste water solution remaining after
step c) via osmotic membrane distillation to obtain an enriched
alkali metal chloride-containing solution; [0027] f)
electrochemically oxidating of at least a portion of the alkali
metal chloride-containing solution from e) to obtain chlorine, an
alkali metal hydroxide solution and, optionally, hydrogen.
[0028] Another embodiment of the present invention is the above
process, further comprising, in a step d), separating solvent
residues and, optionally, catalyst residues (d1) from the
alkali-metal-chloride-containing reaction waste water solution
remaining after step c) and subsequently feeding the resulting
solution to the osmotic membrane distillation in step e).
[0029] Another embodiment of the present invention is the above
process, wherein step d) is achieved by extracting or stripping the
alkali metal chloride-containing reaction waste water solution with
steam and/or subsequently treating the alkali metal
chloride-containing reaction waste water solution with an adsorbent
(d2).
[0030] Another embodiment of the present invention is the above
process, wherein the adsorbent (d2) is activated charcoal.
[0031] Another embodiment of the present invention is the above
process, wherein the osmotic membrane distillation in step e) uses
an alkali metal hydroxide solution as a water acceptor.
[0032] Another embodiment of the present invention is the above
process, wherein the osmotic membrane distillation in step e) is
operated at a temperature in the range of from 10 to 100.degree.
C.
[0033] Another embodiment of the present invention is the above
process, wherein the osmotic membrane distillation in step e) is
operated at a temperature in the range of from 20 to 50.degree.
C.
[0034] Another embodiment of the present invention is the above
process, wherein the osmotic membrane distillation in step e) is
operated at an absolute pressure in the range of from 1.0 to 1.4
bar
[0035] Another embodiment of the present invention is the above
process, wherein the osmotic membrane distillation in step e) is
operated at an absolute pressure in the range of from 1.1 to 1.2
bar.
[0036] Another embodiment of the present invention is the above
process, wherein the osmotic membrane distillation in step e) is
operated at a differential pressure in the range of from 20 to 150
bar.
[0037] Another embodiment of the present invention is the above
process, wherein the osmotic membrane distillation in step e) is
operated at a differential pressure in the range of from 30 to 100
bar.
[0038] Another embodiment of the present invention is the above
process, wherein the osmotic membrane distillation in step e) uses
an an Accurel PP membrane.
[0039] Another embodiment of the present invention is the above
process, wherein at least a portion of the alkali metal
chloride-containing solution obtained in step e) is added to the
brine circuit of a membrane electrolysis for producing chlorine,
sodium hydroxide solution and, optionally, hydrogen.
[0040] Another embodiment of the present invention is the above
process, wherein additional alkali metal chloride for increasing
the alkali metal chloride concentration is added to the alkali
metal chloride-containing solution in the electrolysis in step
f).
[0041] Another embodiment of the present invention is the above
process, wherein, in d1), before treatment with an absorbent (d2),
the pH of the alkali metal chloride-containing reaction waste water
solution remaining after the separation in step c) is set to below
8.
[0042] Another embodiment of the present invention is the above
process, wherein the at least one bisphenol is of the general
formula
HO--Z--OH
wherein Z is an aromatic moiety having from 6 to 45 carbon atoms,
wherein said aromatic moiety optionally contains one or more
aromatic rings, is optionally substituted, and optionally contains
aliphatic moieties or cycloaliphatic moieties or heteroatoms as
bridging units.
[0043] Another embodiment of the present invention is the above
process, wherein the at least one bisphenol is selected from the
group consisting of hydroquinone, resorcinol, dihydroxybiphenyls,
bis(hydroxyphenyl)alkanes, bis(hydroxyphenyl)cycloalkanes,
bis(hydroxyphenyl)sulphides, bis(hydroxyphenyl)ethers,
bis(hydroxyphenyl)ketones, bis(hydroxyphenyl)sulphones,
bis(hydroxyphenyl)sulphoxides,
.alpha.,.alpha.'-bis(hydroxyphenyl)diisopropylbenzenes,
bis(hydroxyphenyl)phthalimidines, and alkylated, ring-alkylated,
and ring-halogenated compounds thereof.
[0044] Another embodiment of the present invention is the above
process, wherein the at least one bisphenol is selected from the
group consisting of 4,4'-dihydroxydiphenyl,
2,2-bis(4-hydroxyphenyl)-1-phenylpropane,
1,1-bis(4-hydroxyphenyl)phenylethane,
2,2-bis(4-hydroxyphenyl)propane,
2,4-bis(4-hydroxyphenyl)-2-methylbutane,
1,3-bis[2-(4-hydroxyphenyl)-2-propyl]benzene,
2,2-bis(3-methyl-4-hydroxyphenyl)-propane,
bis(3,5-dimethyl-4-hydroxyphenyl)methane,
2,2-bis(3,5-dimethyl-4-hydroxyphenyl)propane,
bis(3,5-dimethyl-4-hydroxyphenyl)sulphone,
2,4-bis(3,5-dimethyl-4-hydroxyphenyl)-2-methylbutane,
1,3-bis[2-(3,5-dimethyl-4-hydroxy-phenyl)-2-propyl]benzene,
2-hydrocarbyl-3,3-bis(4-hydroxyphenyl)phthalimidine,
3,3-bis(4-hydroxyphenyl)-1-phenyl-1H-indol-2-one,
2,2-bis(4-hydroxyphenyl)-1-phenyl-1H-indol-2-one,
3,3-bis(4-hydroxyphenyl)-1-methyl-1H-indol-2-one,
2,2-bis(4-hydroxyphenyl)-1-methyl-1H-indol-2-one,
3,3-bis(4-hydroxyphenyl)-N-methylphthalimidine,
3,3-bis(4-hydroxyphenyl)-N-phenyl-phthalimidine, and
1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane.
[0045] Another embodiment of the present invention is the above
process, wherein step c) comprises at least the following substeps:
[0046] aa) separating an organic phase comprising the polycarbonate
formed in step b) from the alkali metal chloride-containing
reaction waste water solution; and [0047] bb) washing the organic
phase obtained in step aa) at least once; wherein at least a
portion of the wash phase(s) from bb), optionally after separation
of catalyst residues and/or organic solvent residues, is used as a
partial substitute of the water for producing the aqueous alkali
metal hydroxide solution for use in step b).
[0048] Another embodiment of the present invention is the above
process, wherein the alkali metal of the alkali metal
chloride-containing reaction waste water solution is sodium.
BRIEF DESCRIPTION OF THE DRAWING
[0049] FIG. 1 depicts an embodiment of the present invention.
DESCRIPTION OF THE INVENTION
[0050] It has been found that in the continuous production of
polycarbonate by reaction of bisphenols and phosgene in an inert
solvent or solvent mixture in the presence of alkali metal and
nitrogen catalyst, improved recycling of sodium chloride from the
sodium chloride-containing waste water solutions occurring in the
boundary phase can be achieved, the sodium chloride-containing
waste water solutions occurring in the boundary phase can be
concentrated without complex purification directly in an osmotic
membrane distillation after setting the pH to a pH less than or
equal to 8 and after simple treatment with activated carbon, and
electrochemical oxidation of the resultant sodium chloride to give
chlorine, sodium hydroxide solution and optionally hydrogen can be
achieved, wherein the chlorine can be recycled for producing the
phosgene.
[0051] The invention therefore relates to a process for producing
polycarbonate and utilizing the resultant waste water phases. In
particular, the process comprises concentration, by osmotic
membrane distillation, of the alkali metal chloride-containing
waste water phases occurring in the polycarbonate production
process, for processing in a downstream alkali metal chloride
electrolysis. In the process, optionally, simultaneously a sodium
hydroxide solution formed in the electrolysis can be diluted which
can be used subsequently directly as starting material in the
polycarbonate process.
[0052] The process according to the invention comprises at least
the following steps: [0053] (a) producing phosgene by reacting
chlorine with carbon monoxide, [0054] (b) reacting the phosgene
formed as per step a) with at least one bisphenol in the presence
of an aqueous alkali metal-containing base, in particular a
sodium-containing base, if appropriate a nitrogen catalyst, and if
appropriate organic solvent, to form a polycarbonate and an alkali
metal chloride-containing reaction waste water solution, in
particular a sodium chloride-containing reaction waste water
solution, [0055] (c) separating off and working up the
polycarbonate formed in step b), [0056] (d) if appropriate
separating off the solvent residues and, if appropriate catalyst
residues, from the alkali metal chloride-containing solution (d1)
remaining from step c), in particular by extraction or stripping
the solution with steam and subsequent treatment with adsorbents
(d2), in particular with activated carbon, [0057] (e) osmotic
membrane distillation of at least some of the alkali metal
chloride-containing solution remaining from step c) or d) [0058]
(f) electrochemical oxidation of at least some of the alkali metal
chloride-containing solution from e), forming chlorine, alkali
metal hydroxide solution and, if appropriate, hydrogen.
[0059] In a particularly preferred embodiment, the process is
characterized in that, after the substep d1), before the treatment
with adsorbents (d2), the solution is adjusted to a pH less than or
equal to 8, preferably 6 to 8.
[0060] In a further particular embodiment, at least some of the
chlorine produced according to step f) is recycled to the
production of phosgene according to step a).
[0061] In a further preferred embodiment, at least some of the
alkali metal hydroxide solution produced according to step f) is
used as water acceptor in the osmotic membrane distillation
according to step e).
[0062] In a further particularly preferred embodiment, at least
some of the dilute alkali metal hydroxide solution obtained
according to step e) is recycled to the production of polycarbonate
according to step b).
[0063] The alkali metal chloride-containing solution obtained after
the separation according to step c) (reaction waste water) can be
used in the osmotic membrane distillation, alone or combined with
the wash phases from the workup (total process waste water),
preferably alone, after optional separation of solvent residues
and, if appropriate catalyst residues, according to step d).
[0064] Suitable bisphenols are those of the general formula
HO--Z--OH,
where Z is an aromatic moiety having 6 to 45 carbon atoms which can
contain one or more aromatic rings, can be substituted and can
contain aliphatic moieties or cycloaliphatic moieties or
heteroatoms as bridging units can be used. Examples of such
compounds which can be used in the process according to the
invention are dihydroxydiarylalkanes such as hydroquinone,
resorcinol, dihydroxybiphenyl, bis(hydroxyphenyl)alkanes,
bis(hydroxyphenyl)cycloalkanes, bis(hydroxyphenyl)sulphides,
bis(hydroxyphenyl)ethers, bis(hydroxyphenyl)ketones,
bis(hydroxyphenyl)sulphones, bis(hydroxyphenyl)sulphoxides,
.alpha.,.alpha.'-bis(hydroxyphenyl)diisopropylbenzenes,
bis(hydroxyphenyl)phthalimidines and also alkylated, ring-alkylated
and ring-halogenated compounds thereof.
[0065] Preferred bisphenols are 4,4'-dihydroxydiphenyl,
2,2-bis(4-hydroxyphenyl)-1-phenylpropane,
1,1-bis(4-hydroxyphenyl)phenylethane,
2,2-bis(4-hydroxyphenyl)-propane (bisphenol A, BPA),
2,4-bis(4-hydroxyphenyl)-2-methylbutane,
1,3-bis[2-(4-hydroxyphenyl)-2-propyl]benzene (bisphenol M),
2,2-bis(3-methyl-4-hydroxyphenyl)propane,
bis(3,5-dimethyl-4-hydroxyphenyl)methane,
2,2-bis(3,5-dimethyl-4-hydroxyphenyl)propane,
bis(3,5-dimethyl-4-hydroxyphenyl)sulphone,
2,4-bis(3,5-dimethyl-4-hydroxyphenyl)-2-methylbutane, 1,3-bis
[2-(3,5-dimethyl-4-hydroxyphenyl)-2-propyl]benzene,
1,1-bis(4-hydroxyphenyl)cyclohexane,
2-hydrocarbyl-3,3-bis(4-hydroxyaryl)phthalimidine,
3,3-bis(4-hydroxyaryl)-1-aryl-1H-indol-2-one,
2,2-bis(4-hydroxyaryl)-1-aryl-1H-indol-2-one, and
1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane (bisphenol
TMC).
[0066] Particularly preferred bisphenols are
4,4'-dihydroxydiphenyl, 1,1-bis(4-hydroxyphenyl)phenylethane,
2,2-bis(4-hydroxyphenyl)propane (bisphenol A (BPA)),
2,2-bis(3,5-dimethyl-4-hydroxyphenyl)propane,
1,1-bis(4-hydroxyphenyl)cyclohexane,
2-hydrocarbyl-3,3-bis(4-hydroxyphenyl)phthalimidine,
3,3-bis(4-hydroxyphenyl)-1-phenyl-1H-indol-2-one,
2,2-bis(4-hydroxyphenyl)-1-phenyl-1H-indol-2-one,
3,3-bis(4-hydroxyphenyl)-1-methyl-1H-indol-2-one,
2,2-bis(4-hydroxyphenyl)-1-methyl-1H-indol-2-one,
3,3-bis(4-hydroxyphenyl)-N-methylphthalimidine,
3,3-bis(4-hydroxyphenyl)-N-phenylphthalimidine and
1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane (bisphenol
TMC).
[0067] These and other suitable bisphenols are described, e.g. in
U.S. Pat. No. 2,970,131 A, U.S. Pat. No. 2,991,273 A, U.S. Pat. No.
2,999,835 A, U.S. Pat. No. 2,990,846 A, U.S. Pat. No. 3,028,365 A,
U.S. Pat. No. 3,062,781 A, U.S. Pat. No. 3,148,172 A, U.S. Pat. No.
3,271,367 A, U.S. Pat. No. 3,275,601 A, U.S. Pat. No. 3,271,367 A
and U.S. Pat. No. 4,982,014 A, in the German laid-open publications
DE 1 570 703 A, DE 2 063 050 A, DE 2 036 052 A, DE 2 211 956 A, DE
3 832 396 A and DE 38 33 953 A, the French patent document FR 1 561
518, in the monograph by H. Schnell, Chemistry and Physics of
Polycarbonates, Interscience Publishers, New York 1964, pp. 28ff;
page 102ff and by D. G. Legrand, J. T. Bendler, Handbook of
Polycarbonate Science and Technology, Marcel Dekker New York 2000,
pp. 72ff.
[0068] It may be emphasized here that the process according to the
invention can be used virtually for all known bisphenols.
[0069] Suitable chain stoppers and branching agents are known from
the literature. Some are described, for example, in DE 38 33 953 A.
Preferred chain stoppers are phenol, cumylphenol, isooctylphenol
and para-tert-butylphenol.
[0070] Preferred branching agents are trisphenols and tetraphenols
and also
3,3-bis(3-methyl-4-hydroxyphenyl)-2-oxo-2,3-dihydroindole.
[0071] The alkali metal used for forming the bisphenolate can be an
alkali metal hydroxide solution having hydroxides from the series:
Na, K, Li hydroxide, if appropriate, alkaline earth metal
hydroxides can also be used. Preference is given to sodium
hydroxide solution and, in the novel process, is preferably used as
a 10 to 55% by weight solution.
[0072] Catalysts which come into consideration for the reaction b)
are all catalysts known for the production of polycarbonates by the
two-phase boundary layer method, such as tertiary amines,
N-alkylpiperidines or pyridine.
[0073] The amine catalyst used can be open-chain or cyclic,
particular preference is given to triethylamine and
ethylpiperidine. The catalyst is used in the novel process
preferably as a 1 to 55% by weight solution.
[0074] Phosgene can be used in the process step b) in the liquid
state, gaseous state or dissolved in an inert solvent.
[0075] In the novel process, in step b), inert organic solvents
which are preferably usable are all known solvents which are able
to dissolve polycarbonate by at least 5% by weight at temperatures
around 20.degree. C., and also mixtures thereof. Preference is
given, for example, to dichloromethane, toluene, the various
dichloroethanes and chloropropane compounds, chlorobenzene and
chlorotoluene. Preferably, dichloromethane, or a mixture of
dichloromethane and chlorobenzene is used. Particular preference is
given to dichloromethane and mixtures of dichloromethane and
monochlorobenzene in the ratio of 20:80 parts by weight to 75:25
parts by weight.
[0076] Over the entire reaction, a pH between 9 and 14 is set,
preferably between 9.5 and 13.0. This is achieved in that once at
the start the amount of alkali metal hydroxide solution necessary
to dissolve the bisphenols is used and, furthermore, upstream of
the heat exchanger a first resupply of the alkali metal hydroxide
solution is performed, and subsequently thereto upstream of the
tubular reactors, if appropriate together with the chain stopper a
second resupply of the alkali metal hydroxide solution is
performed.
[0077] The polycarbonates attainable by the process according to
the invention can be used industrially in a known manner as any
desired shaped bodies or else plates and films, for example in the
car sector or in optical applications, optical and magneto-optic
storage media.
[0078] The reaction profile for step b) proceeds preferably
continuously and particularly preferably in plug flow without great
back-mixing. This can be achieved, therefore, for example in
tubular reactors. The mixing of the two phases (aqueous and organic
phase) can be effected by installed tube orifices, static mixers
and/or, for example, pumps.
[0079] The reaction according to step b) proceeds particularly
preferably in two stages.
[0080] In the first stage of the preferred process, the reaction is
started by bringing together the starting materials phosgene, the
inert solvent or solvent mixture, which preferably acts only as
solvent for the phosgene, and the bisphenol, which preferably is
already dissolved in advance in the alkali metal hydroxide
solution. The residence time in the first stage is typically in the
range from 2 seconds to 300 seconds, particularly preferably in the
range from 4 seconds to 200 seconds. The pH of the first stage is
set by the ratio of alkali metal hydroxide
solution/bisphenol/phosgene in such a manner that the pH is in the
range from 11.0 to 12.0, preferably 11.2 to 11.8, particularly
preferably 11.4 to 11.6. The reaction temperature of the first
stage is held by cooling preferably <40.degree. C., particularly
preferably <35.degree. C.
[0081] In the second stage of the preferred process, the reaction
to give the polycarbonate is completed. The residence time in the
preferred process is 1 minute to 2 hours, preferably 2 minutes to 1
hour, very particularly preferably 3 minutes to 30 minutes. In the
second stage of the preferred process, control is performed by
permanent monitoring of the pH (in the continuous process this is
preferably measured on-line by processes which are known in
principle) and corresponding adjustment of the pH by addition of
the alkali metal hydroxide solution. The amount of alkali metal
hydroxide solution fed is set, in particular, such that the pH of
the reaction mixture in the second process stage is in the range
from 7.5 to 10.5, preferably 8 to 9.5, very particularly preferably
8.2 to 9.3. The reaction temperature of the second stage is held by
cooling at preferably <50.degree. C., particularly preferably
<40.degree. C., very particularly preferably <35.degree.
C.
[0082] The parameters or comments listed in this application
generally or in preferred ranges can, however, also be combined as
desired among themselves, that is to say between the respective
ranges and preferred ranges.
[0083] In the preferred process, in step b), phosgene is used in
relation to the bisphenol in the molar ratio of 1:2 to 1:2.2. The
solvent is added in such a manner that the polycarbonate is in a 5
to 60% by weight solution, preferably 20 to 45% by weight solution
after the reaction.
[0084] The concentration of the catalyst is preferably 0.0001 mol
to 0.1 mol, based on the bisphenol used.
[0085] After the reaction b), in step c), preferably the organic,
polycarbonate-containing phase is customarily washed with an
aqueous liquid and separated from the aqueous phase as far as
possible after each washing operation. The washes are preferably
performed with demineralized water. The polycarbonate solution,
after the washing and separation of the washing liquid, is
customarily cloudy. As washing liquid, aqueous liquids for
separating off the catalyst, e.g. a dilute mineral acid such as HCl
or H.sub.3PO.sub.4, are used, and for further purification
demineralized water. The concentration of HCl or H.sub.3PO.sub.4 in
the wash liquid can be, for example, 0.5 to 1.0% by weight. The
organic phase is preferably washed, for example, once, preferably
several times.
[0086] Phase separation devices which can be used for separating
off the wash liquid from the organic phase can be separation
vessels, phase separators, centrifuges or coalescers which are
known in principle, or else combinations of these appliances.
[0087] This gives, in this manner, without taking into account the
solvent which is still to be separated off, surprisingly high
degrees of purity of the polycarbonate of >99.85%.
[0088] In a preferred embodiment of the process according to the
invention, the wash liquids which are separated off in step c), if
appropriate after separation of catalyst residues and/or organic
solvent residues, can be recycled back into the process according
to the invention.
[0089] The separation and workup according to step c) of the
polycarbonate formed in step b) can preferably comprise at least
the following steps: [0090] aa) separation of
polycarbonate-containing organic phase and aqueous alkali metal
chloride-containing reaction waste water solution [0091] bb)
washing at least once, preferably at least twice, particularly
preferably five times, the polycarbonate-containing organic phase
obtained in step aa) and separating off the respective wash
liquid.
[0092] If appropriate it can be necessary to separate at least one
of the wash liquid(s) obtained according to step c) bb) from
catalyst residues and if appropriate organic solvent residues by
setting the pH to at least 9, preferably at least 10, particularly
preferably 10 to 11, by addition of at least one basic compound,
and to subject it to a subsequent extraction with at least one
inert organic solvent, or preferably to subsequent stripping of the
solution with steam. Suitable basic compounds for setting the pH
are, for example, alkali metal or alkaline earth metal hydroxides
or carbonates. The basic compounds can be used in solid form or in
the form of their aqueous solutions. Preferably, alkali metal
hydroxide solutions are used, particularly preferably sodium
hydroxide solution. In step (d1), also, these pHs are preferably
set using the abovementioned compounds.
[0093] Preferably, at least some of the wash liquid(s) from step c)
bb) can be used as partial replacement of the water for the
production, in particular for setting the concentration of the
sodium hydroxide solution for step b). In a preferred embodiment of
the process according to the invention, at least some of the wash
liquid(s) from step c) bb) can be used for diluting the alkali
metal hydroxide solution produced according to step e) and/or f),
before they are recycled into the production of polycarbonate
according to step b).
[0094] The preferred embodiment of the process according to the
invention in which the wash liquids separated off in step c) are
recirculated back to the process according to the invention offers
the additional advantage of lower waste water emission.
[0095] After the synthesis of the polycarbonate, the polycarbonate
is separated off in the form of its solution in the organic solvent
or solvent mixture used in the synthesis, for example methylene
chloride or methylene chloride/chlorobenzene.
[0096] For obtaining the high-purity polycarbonate, the solvent is
evaporated. The evaporation can proceed in a plurality of
evaporator stages. For example, this is performed by one or more
series-connected distillation columns in which the solvent is
separated off from the polycarbonate.
[0097] The purification stage c) or stages can be carried out, for
example, continuously, in such a manner that the pot temperature in
the distillation is 150.degree. C. to 310.degree. C., preferably
160 to 230.degree. C. The pressure employed for carrying out this
distillation is in particular 1 to 1000 mbar, preferably 5 to 100
mbar.
[0098] The polycarbonates thus purified are distinguished by very
good product properties, and so subsequently shaped parts can be
produced therefrom in excellent quality.
[0099] The remaining alkali metal chloride-containing solution
according to step c) is advantageously freed from highly volatile
organic impurities such as, e.g., residues of the organic solvent
used in the synthesis and if appropriate catalyst, for example by
distillation or steam stripping. There then remains a waste water
having a high content of dissolved sodium chloride (5-10% by
weight) and dissolved sodium carbonates (0.3-1.5% by weight). The
carbonates are formed, e.g., by hydrolysis of the phosgene as a
side reaction of polycarbonate production. In addition, the waste
water is polluted with organic compounds, e.g. with phenols (e.g.
unsubstituted phenol, alkylphenols).
[0100] The treatment of the prepurified waste water with adsorbents
then preferably proceeds using activated carbon.
[0101] According to a preferred process, the pH is reduced using
hydrochloric acid or hydrogen chloride after the process substep
d1) before treatment with absorbents (d2). Preferably, the pH is
reduced to less than 8, particularly preferably to 4 to 8. The use
of the cheaper sulphuric acid, which is conceivable in principle,
but unwanted in the present process, would lead to sodium sulphate
being formed in the pH reduction such that it would be enriched in
the subsequent electrolysis in the anolyte circuit. Since, e.g. the
ion-exchange membranes, according to the manufacturer's
instructions, may only be operated up to a certain sodium sulphate
concentration in the anolyte, more anolyte would have to be ejected
than when hydrochloric acid or hydrogen chloride is used, the
reaction product of which is the wanted sodium chloride.
[0102] A preferred process variant is that water is removed from
the alkali metal chloride-containing waste water by a concentration
process.
[0103] Increasing concentration of NaCl solutions by osmotic
distillation is energy-saving, in particular when, in a preferred
embodiment, the NaOH solution originating from the NaCl
electrolysis is used as water acceptor. This has advantages,
particularly when in the polycarbonate production a dilute sodium
hydroxide solution is used, in which case, additionally the water
for diluting the sodium hydroxide solution can be saved.
[0104] Particular preference is therefore given to a process
characterized in that the concentration of the alkali metal
chloride-containing solution from d), before the electrolysis f),
is increased by means of osmotic distillation in step e) using
sodium hydroxide solution as water acceptor.
[0105] By combination of operation of the electrolysis cells
according to the invention and concentration increase process
according to the invention, theoretically up to 68% of the sodium
chloride can be recovered from the waste water. This applies to the
case that the sodium chloride electrolysis produces only the
chlorine required for the phosgene production and the sodium
hydroxide solution required for the polycarbonate production, and
no chlorine for other applications.
[0106] The osmotic distillation proceeds via molecular diffusion
and, if appropriate, Knudsen diffusion, of steam through a
membrane. The diffusion rate is thereby dependent on the difference
between the steam pressures on both sides of the membrane, and also
on its porosity, thickness and tortuosity.
[0107] In order to enable efficient increase of concentration, a
concentrated solution of an alkali metal hydroxide, preferably
sodium hydroxide or potassium hydroxide, particularly preferably
sodium hydroxide, should be used as water acceptor.
[0108] For the process according to the invention, a chemically
resistant material such as, e.g. polypropylene, should be used as
membrane material. The membranes used should preferably be
capillary membranes having a capillary length of 30-6000 .mu.m, and
a diameter of 0.01 to 0.7 .mu.m.
[0109] Particularly suitable membranes are lipophilic membranes
such as, for example, Accurel PP 50/200, Accurel PP 50/280, Accurel
PP 150/330, Accurel PP Q3/2 or Accurel S 6/2 from the Membrana
company.
[0110] The process is preferably operated in such a manner that the
osmotic distillation is operated at a temperature of 10 to
100.degree. C., preferably 20 to 50.degree. C. The temperature of
the sodium hydroxide solution used can be higher than that of the
NaCl-containing waste water.
[0111] The osmotic distillation is operated at an absolute pressure
of 1 to 1.4 bar, preferably at a pressure of 1.1 to 1.2 bar.
[0112] The pressure ratios between alkali metal chloride solution
and alkali metal hydroxide solution are selected in such a manner,
in particular, that the osmotic pressure of the alkali metal
chloride solution is higher than the pressure of the alkali metal
hydroxide solution.
[0113] The differential pressure between alkali metal chloride
solution and alkali metal hydroxide solution should be, in a
particularly preferred process, 20 to 150 bar, preferably 30 to 100
bar.
[0114] The alkali metal chloride electrolysis process will be
described in more detail hereinafter. The description hereinafter
may be considered by way of example with reference to the
electrolysis of sodium chloride, since in the process as described
above, in principle any alkali metal chloride can be used (in
particular LiCl, NaCl, KCl), but the use of sodium chloride or
sodium hydroxide solution in the above stages is the preferred
embodiment of the process.
[0115] Customarily, e.g. for the electrolysis of
sodium-chloride-containing solutions, membrane electrolysis
processes are used (see in this context Peter Schmittinger,
CHLORINE, Wiley-VCH Verlag, 2000). In this case a two-part
electrolysis cell is used which consists of an anode chamber having
an anode and a cathode chamber having a cathode. Anode chamber and
cathode chamber are separated by an ion-exchange membrane. A sodium
chloride-containing solution having a sodium chloride concentration
of customarily more than 300 g/l is introduced into the anode
chamber. At the anode the chloride ion is oxidized to chlorine
which is conducted out of the cell together with the depleted
sodium chloride-containing solution (approximately 200 g/l). The
sodium ions migrate under the influence of the electric field
through the ion-exchange membrane into the cathode chamber. During
this migration each mol of sodium, depending on the membrane, is
accompanied by between 3.5 and 4 mol of water. As a result, the
anolyte becomes depleted in water. In contrast to the anolyte, on
the cathode side, owing to the electrolysis of water to hydroxide
ions and hydrogen, water is consumed. The water passing together
with the sodium ions into the catholyte is sufficient to keep the
sodium hydroxide solution concentration in the effluent to 31-32%
by weight, this at an intake concentration of 30% by weight and a
current density of 4 kA/m.sup.2. In the cathode chamber, water is
electrochemically reduced, wherein hydroxide ions and hydrogen are
formed.
[0116] Alternatively, also a gas diffusion electrode can be used as
cathode, at which oxygen is reacted with electrons to give
hydroxide ions, with no hydrogen being formed. The hydroxide ions
form sodium hydroxide solution together with the sodium ions which
have passed into the cathode chamber via the ion-exchange membrane.
A sodium hydroxide solution having a concentration of 30% by weight
is customarily fed into the cathode chamber and a sodium hydroxide
solution having a concentration of 31-32% by weight removed. The
purpose is to achieve a sodium hydroxide solution concentration as
high as possible, since customarily the sodium hydroxide solution
is stored or transported as a 50% by weight hydroxide solution.
Commercially available membranes, however, are currently not stable
to a hydroxide solution having a higher concentration than 32% by
weight, and so the sodium hydroxide solution must be concentrated
by thermal evaporation.
[0117] In the case of the sodium chloride electrolysis, additional
water is introduced into the anolyte via this sodium
chloride-containing solution, but only water is discharged via the
membrane into the catholyte. If more water is introduced via the
sodium-chloride-containing solution than can be transported to the
catholyte, the anolyte becomes depleted in sodium chloride and the
electrolysis cannot be operated continuously. At very low sodium
chloride concentrations, the side reaction of oxygen formation
would start.
[0118] In order to feed maximum amounts of sodium
chloride-containing solutions economically to the sodium chloride
electrolysis, it can be useful that the water transport via the
membrane is increased. This can be performed by selection of
suitable membranes such as described in U.S. Pat. No. 4,025,405 A.
The effect of increased water transport is that the otherwise
customary water addition to maintain the hydroxide solution
concentration can be omitted.
[0119] According to U.S. Pat. No. 3,773,634 A, at high water
transport through the membrane, the electrolysis can be operated
when a hydroxide solution concentration of 31 to 43% by weight and
a sodium chloride concentration of 120 to 250 g/l are used.
[0120] A disadvantage of both processes is the lower current yield
of these processes, which impairs the economic efficiency of the
electrolysis.
[0121] According to the preferred process, the sodium
chloride-containing reaction waste water is separated off d2) after
the phase separation and the removal of the solvent and catalyst
used if appropriate, by extraction or stripping with steam and,
after setting the pH, via an activated carbon treatment.
[0122] Hereafter, the alkali metal-chloride-containing waste water
can be fed directly to the osmotic distillation e).
[0123] Compared with the prior art (WO 03/70639 A), in which a
maximum 13% of the sodium chloride present in the waste water of
the polycarbonate production can be used in the NaCl electrolysis,
by means of the process according to the invention, more than 13%
of the sodium chloride can be recovered from the waste water.
[0124] The novel process can also be carried out using an alkali
metal chloride electrolysis in which no hydrogen is generated at
the cathode, but the cathode is replaced by a gas-diffusion
electrode at which oxygen is reduced to hydroxide ions.
[0125] If, e.g. in an integrated site, no hydrogen is required for
chemical reactions, the obligatorily produced hydrogen can be
dispensed with. The advantage is an energy saving in the
electrolysis, attributable to the lower electrolysis voltage when a
gas-diffusion electrode is used.
[0126] The sodium chloride-containing solution arriving from the
polycarbonate production customarily has a sodium chloride content
of up to 10% by weight, if it is the reaction waste water. If the
reaction waste water is combined with the wash water, then the NaCl
concentration is, for example approximately 6% by weight. If the
electrolysis delivers the chlorine and the sodium hydroxide
solution exclusively for the polycarbonate production, then the
sodium chloride-containing waste water can only be used to a minor
extent in the electrolysis. For instance, in the case of the
customary ion-exchange membranes and the standard operating
parameters of the sodium chloride electrolysis, only approximately
7% of the sodium chloride of a 6% by weight sodium
chloride-containing polycarbonate waste water solution can be used.
The standard operating parameters of the NaCl electrolysis are a
brine concentration in the effluent of 200 to 240 g/l and an NaOH
concentration of 31-32% by weight. Complete recycling of the sodium
chloride which occurs has therefore not been possible to date.
Concentration by thermal evaporation of the water is not currently
economic, since the sodium chloride is available as a very
inexpensive product.
[0127] Using the process according to the invention, significantly
more than 13% of the sodium chloride from the waste waters
occurring can be recycled at a concentration of 10% by weight, if
the sodium chloride electrolysis provides the chlorine and the
sodium hydroxide solution solely for polycarbonate production.
Customarily, sodium chloride electrolyses are operated at
integrated chemical sites having a plurality of chlorine consumers
and so a sodium chloride-containing solution is not available for
recycling from all consumers. The fraction of reusable sodium
chloride from the waste water increases when the sodium chloride
electrolysis has not to provide the sodium hydroxide solution and
the chlorine exclusively for polycarbonate production.
[0128] A further preferred variant of the novel process is that the
concentration of the waste water of the polycarbonate production is
increased by solid alkali metal chloride and is fed to the alkali
metal chloride electrolysis. By this means more than 50% of the
alkali metal chloride from the polycarbonate waste water could be
reused.
[0129] This, however, implies that the chlorine and the alkali
metal hydroxide solution are not used solely for polycarbonate
production.
[0130] Particularly preferably, an alkali metal chloride-containing
waste water having a pH less than 7 is used in or fed to the
electrolysis f). The pH is adjusted preferably using hydrochloric
acid, but can also be adjusted using gaseous hydrogen chloride. In
a further preferred process, the NaCl electrolysis is operated in
such a manner that the NaCl solution which arrives from the cell,
has an NaCl concentration of less than 200 g/l. Concurrently, the
hydroxide solution exiting the cell may have a concentration of
less than 30% by weight.
[0131] The transport of water through the ion-exchange membrane
depends not only on the operating parameters, but also on the type
of membrane used. The process according to the invention utilizes
such ion-exchange membranes which under the conditions according to
the invention of the sodium chloride concentration and hydroxide
solution concentration, enable transport of water through the
membrane of more than 4.5 mol of water per mol of sodium.
[0132] The current density is calculated in this process on the
basis of the membrane area and is, in particular, 2 to 6
kA/m.sup.2. Particularly preferably, anodes having a relatively
high surface area are used. Anodes having a relatively high surface
area are taken to mean those in which the physical surface area is
significantly greater than the projected surface area. Anodes
having a relatively high surface area are, e.g., electrodes
constructed in a foam-like or felt-like manner. By this means at
the anode, a very high electrode surface area is offered and the
local current density is greatly decreased. The surface area of the
anode is preferably selected in such a manner that the local
current density, based on the physical surface area of the
electrode, is less than 3 kA/m.sup.2. The higher the surface area
and the lower the local current density, the lower the sodium
chloride concentration in the brine can be selected and the greater
is the fraction of sodium chloride from the waste water which can
be recycled.
[0133] The pH of the alkali metal chloride-containing waste water,
before the electrolysis f), should preferably be less than 7,
particularly preferably 0.5 to 6.
[0134] The alkali metal chloride electrolysis should be operated in
such a manner that the alkali metal chloride concentration of the
alkali metal chloride solution arriving from the cell is between
100 to 280 g/l of sodium chloride and/or such that the
concentration of the alkali metal hydroxide solution which arrives
from the cell is 13 to 33% by weight. Particular preference is
given to concentrations which enable operation of the cell at
relatively low voltages. For this, the concentration of the alkali
metal chloride solution arriving from the cell should preferably
between 110 to 220 g/l of alkali metal chloride and/or the
concentration of the alkali metal hydroxide solution which arrives
from the cell should be 20 to 30% by weight.
[0135] The ion-exchange membranes used in the electrolysis should
have a transport of water per mol of sodium of preferably greater
than 4.0 mol of H.sub.2O/mol of sodium, particularly preferably 4.5
to 6.5 mol of H.sub.2O/mol of sodium.
[0136] The process is preferably operated in such a manner that the
electrolysis f) is carried out at a temperature of 70 to
100.degree. C., preferably at 80 to 95.degree. C.
[0137] The electrolysis is operated at an absolute pressure of 1 to
1.4 bar, preferably at a pressure of 1.1 to 1.2 bar.
[0138] The pressure ratios between anode chamber and cathode
chamber are selected, in particular, in such a manner that the
pressure in the cathode chamber is higher than the pressure in the
anode chamber.
[0139] The differential pressure between cathode chamber and anode
chamber should be, in a particularly preferred process, 20 to 150
mbar, preferably 30 to 100 mbar.
[0140] At lower alkali metal chloride concentrations, special anode
coatings can also be used. In particular, the coating of the anode
can contain, in addition to ruthenium oxide, also other noble metal
components of subgroup 7 and 8 of the Periodic Table of the
Elements. For example, the anode coating can be doped with
palladium compounds. Coatings based on diamonds are equally
usable.
[0141] The examples hereinafter are intended to illustrate the
present invention, without restricting it however.
[0142] All the references described above are incorporated by
reference in their entireties for all useful purposes.
[0143] While there is shown and described certain specific
structures embodying the invention, it will be manifest to those
skilled in the art that various modifications and rearrangements of
the parts may be made without departing from the spirit and scope
of the underlying inventive concept and that the same is not
limited to the particular forms herein shown and described.
Examples
[0144] The examples are intended to describe the process according
to the invention with reference to concentrating the sodium
chloride-containing waste water phases occurring in the production
of polycarbonate and the simultaneous dilution of the sodium
hydroxide solution obtained from the electrolysis for the
polycarbonate production process by osmotic membrane distillation
and electrolysis of the resultant sodium chloride-containing
solutions.
Example 1
[0145] a) Production and Workup of the Polycarbonate
[0146] In a pumped circulation reactor, upstream of the pump, 24
000 kg/h of an alkaline Bisphenol A solution which contains 15% by
weight of BPA and 2.1 mol of sodium hydroxide solution per mol of
BPA are metered in via a T piece, and also via a further T piece
1848 kg/h of phosgene dissolved in 20 400 kg/h of solvent which
consists of 50% by weight of methylene chloride and 50% by weight
of monochlorobenzene are metered in.
[0147] To maintain the alkalinity, 360 kg/h of 32% by weight sodium
hydroxide solution are added and the reaction mixture is passed via
a heat exchanger and an unstirred dwell time vessel back to the
pump, wherein the above mentioned mass streams are added.
[0148] By means of flow metering, the pumped circulation rate is
determined at 260 m.sup.3/h.
[0149] The temperature is 36.degree. C.
[0150] A subquantity of the emulsion, which is equal in size to the
influent raw materials, is fed upstream of the metering points for
BPA and phosgene from the dwell time vessel of a further pump and
pumped through a tubular reactor. To this stream are added 1050
kg/h of sodium hydroxide solution (32% by weight) and also 134 kg/h
of p-tert-butylphenol, dissolved in 536 kg of solvent mixture.
After a dwell time of 10 min, 18 kg/h of N-ethylpiperidine are
added in the form of a 4.8% by weight solution in solvent mixture
(50 parts of methylene chloride and 50 parts of monochlorobenzene)
and the emulsion is pumped by means of a further pump through a
further tubular reactor.
[0151] After a dwell time of a further 10 min, the emulsion is
separated in a separation vessel and the polycarbonate solution is
washed free of electrolyte by known processes, e.g. by a centrifuge
technique.
[0152] The polycarbonate solution is concentrated in evaporation
units and freed from residual solvent on a degassing extruder.
[0153] The following analytical data were determined on the
polycarbonate granules:
[0154] YI=1.35 (measured as specified in ASTM E 313)
[0155] Eta rel=1.195 (measured as specified in ISO 1628/4)
[0156] Phenolic OH=85 ppm (measured by UV spectroscopy at 546 nm
after staining the phenolic end groups with TiCl.sub.4)
[0157] The reaction waste water is not combined here with the wash
phases and is freed from solvent residues and catalyst by stripping
with steam. After neutralizing with hydrochloric acid and treating
with activated carbon, the reaction waste water contains 9.0% by
weight of NaCl and <2 ppm of free BPA and phenols, measured by
UV spectroscopy of the aqueous phase at 294 nm, e.g. in a
Perkin-Elmer spectrometer.
[0158] It can be fed without further purification to the osmotic
membrane distillation.
[0159] b) Increasing Concentration of the Sodium Chloride Solution
(Reaction Waste Water) by Osmotic Membrane Distillation
[0160] The osmotic distillation was carried out at room temperature
in a module which had a membrane surface area of 1 m.sup.2. A
membrane of the Accurel PP 150/330 type from Membrana was used.
Into the module, 2.3 L of the 9.0% by weight sodium
chloride-containing reaction waste water solution from a) were
pumped, whereas 1 L of 31.0% by weight sodium hydroxide solution
was metered in as water-receiving phase in co-current. The
concentration of the reaction waste water solution exiting from the
cell after 210 minutes was 18.0% by weight of NaCl, while the NaOH
solution taken off was depleted to 16.0% by weight.
[0161] The concentrated reaction waste water solution exiting from
the cell can be fed to the electrolysis without further
purification.
[0162] c) Electrochemical Oxidation of the Sodium Chloride Solution
from the Osmotic Distillation
[0163] The electrolysis is carried out, by way of example, in a
laboratory electrolysis cell having an anode surface area of 0.01
m.sup.2. The current density was 4 kA/m.sup.2, temperature at the
outlet on the cathode side 88.degree. C., temperature at the outlet
on the anode side 89.degree. C. An electrolysis cell having a
standard anode and cathode coating from DENORA, Germany was used. A
Nafion 982 WX ion-exchange membrane from DuPont was used. The
electrolysis voltage was 3.02 V. A sodium chloride-containing
solution was circulated through the anode chamber by pumping at a
mass flow rate of 1.0 kg/h. The concentration of the solution fed
to the anode chamber was 25% by weight of NaCl. From the anode
chamber, a 20% by weight NaCl solution could be taken off. To the
NaCl solution taken off from the anode chamber was added 0.137 kg/h
of 18.0% by weight concentrated reaction waste water from the
polycarbonate production and 0.0641 kg/h of solid sodium chloride.
The solution was subsequently fed back to the anode chamber. The
transport of water through the membrane was 3.5 mol of water per
mol of sodium. Of the NaCl solution arriving from the cell, 1% was
discarded, equivalent to 0.008 kg/h of a 20.2% by weight
NaCl-containing solution.
[0164] On the cathode side, a sodium hydroxide solution was
circulated by pumping at a mass flow rate of 1.107 kg/h. The
concentration of the sodium hydroxide solution fed into the cathode
side was 30% by weight of NaOH, and the sodium hydroxide solution
taken off from the cathode side had a concentration of 31.9% by
weight NaOH. Of the 31.9% by weight hydroxide solution, 0.187 kg/h
was taken off from the volume stream and the remainder was
replenished with 0.0664 kg/h of water and recirculated back to the
cathode element. Of the reacted sodium chloride, 27.8% originates
from the polycarbonate reaction waste water.
[0165] d) Recycling the dilute Sodium Hydroxide Solution from the
Osmotic Distillation to the Polycarbonate Production
[0166] The dilute sodium hydroxide solution from b) is fed to the
polycarbonate production. A mixture of 6.5% by weight sodium
hydroxide solution produced by diluting the 16.0% by weight sodium
hydroxide solution from b) with demineralized water, and bisphenol
is combined with a solvent mixture of methylene
chloride/chlorobenzene and phosgene and processed as described in
1a).
[0167] By using the 16.0% by weight sodium hydroxide solution,
instead of the customary 32% by weight sodium hydroxide solution,
25.5% demineralized water can be saved.
Example 2
[0168] a) Production and Workup of the Polycarbonate
[0169] The process as described in example 1a) is carried out, but
the reaction waste water is combined with the wash phases to form
total process waste water and freed from solvent residues and
catalyst by stripping with steam. After neutralization with
hydrochloric acid and treatment with activated carbon, the total
process waste water contains 6.2% by weight NaCl and <2 ppm of
free BPA and phenols, measured by UV spectroscopy of the aqueous
phase at 294 nm, e.g. in a Perkin-Elmer spectrometer. The total
process waste water can be fed to the osmotic membrane distillation
without further purification.
[0170] b) Concentrating the Sodium Chloride Solution (Total Process
Waste Water) by Osmotic Membrane Distillation
[0171] The osmotic distillation was carried out at room temperature
by way of example in a module which had a membrane surface area of
1 m.sup.2. A membrane of the Accurel PP 150/330 type from Membrana
was used. The total process waste water from a) containing 6.2% by
weight sodium chloride was pumped into the module at a flow rate of
19.5 L/h, while 13.0 L/h 33% by weight sodium hydroxide solution
were metered in co-current as water-receiving phase. Owing to the
great reduction in volume of the NaCl solution, 1 L is replenished
once after 20 minutes. The concentration of the process waste water
solution exiting from the cell after 75 minutes was 15.2% by weight
of NaCl, while the NaOH solution taken off was depleted to 16.6% by
weight.
[0172] The enriched total process waste water solution exiting from
the cell can be fed to the electrolysis without further
purification.
[0173] c) Electrochemical Oxidation of the Sodium Chloride Solution
from the Osmotic Distillation
[0174] The electrolysis is carried out by way of example in a
laboratory electrolysis cell having an anode surface area of 0.01
m.sup.2. The current density was 4 kA/m.sup.2, temperature at the
outlet on the cathode side 88.degree. C., temperature at the outlet
on the anode side 89.degree. C. An electrolysis cell having
standard anode and cathode coatings from DENORA, Germany was used.
A DuPont Nafion 982 WX ion-exchange membrane was used. The
electrolysis voltage was 3.02 V. A sodium-chloride-containing
solution was pumped through the anode chamber at a mass flow rate
of 1.0 kg/h. The concentration of the solution fed to the anode
chamber was 25% by weight of NaCl. From the anode chamber, a 20% by
weight NaCl solution could be taken off. To the NaCl solution taken
off from the anode chamber was added 0.132 kg/h of 15.2% by weight
enriched total process waste water from the osmotic membrane
distillation under b) and 0.0686 kg/h of solid sodium chloride. The
solution was subsequently fed back into the anode chamber. The
transport of water through the membrane was 3.5 mol of water per
mol of sodium. Of the NaCl solution arriving from the cell, 1% was
discarded, equivalent to 0.008 kg/h of a 20.2% by weight
NaCl-containing solution.
[0175] On the cathode side, a sodium hydroxide solution was
circulated by pumping at a mass flow rate of 1.107 kg/h. The
concentration of the sodium hydroxide solution fed into the cathode
side was 30% by weight of NaOH, and the sodium hydroxide solution
taken off from the cathode side had a concentration of 31.9% by
weight NaOH, and 0.187 kg/h of the 31.9% by weight hydroxide
solution was taken off from the volume stream, and the remainder
was replenished with 0.0664 kg/h of water and recirculated back to
the cathode element.
[0176] Of the sodium chloride reacted, 22.7% originates from the
polycarbonate total process waste water.
[0177] d) Recycling the Dilute Sodium Hydroxide Solution from the
Osmotic Distillation into the Polycarbonate Production
[0178] The dilute sodium hydroxide solution from b) is fed to the
polycarbonate production. A mixture of 6.5% by weight sodium
hydroxide solution, produced by diluting the 16.6% by weight sodium
hydroxide solution from b) with demineralized water, and bisphenol
is combined with a solvent mixture of methylene
chloride/chlorobenzene, and phosgene and the process as described
in 1 a) is carried out.
[0179] By using the 16.6% by weight sodium hydroxide solution
instead of the customary 32% by weight sodium hydroxide solution,
23.7% of demineralized water can be saved.
Example 3
[0180] a) Production and Workup of the Polycarbonate
[0181] A reaction waste water from the polycarbonate production,
obtained as described in example 1 a), is here not combined with
the wash phases and is freed from solvent residues and catalyst by
stripping with steam. After neutralization with hydrochloric acid
and treatment with activated carbon, the reaction waste water
contains 10% by weight NaCl and <2 ppm of free BPA and phenols,
measured by UV spectroscopy of the aqueous phase at 294 nm, e.g. in
a Perkin-Elmer spectrometer. The reaction waste water can be fed to
the osmotic membrane distillation without further purification.
[0182] b) Increasing Concentration of the Sodium Chloride Solution
(Reaction Waste Water) by Osmotic Membrane Distillation
[0183] The reaction waste water from a) is concentrated to 18.0% by
weight by osmotic membrane distillation according to the process
described in 1b) and fed to the electrolysis with gas-diffusion
electrode.
[0184] c) Electrochemical Oxidation of the Sodium Chloride Solution
from the Osmotic Distillation Using a Gas-Diffusion Electrode
[0185] The concentrated waste water was equivalent in quality as
per example 1b). Since hydrogen is not required for the production
of DPC, the formation of hydrogen during the electrolysis can be
omitted. The electrolysis was therefore operated using
gas-diffusion electrodes. The current density was 4 kA/m.sup.2,
temperature at the outlet on the cathode side 88.degree. C.,
temperature at the outlet on the anode side 89.degree. C. An
electrolysis cell having standard anode coating from DENORA,
Germany was used. A DuPont Nafion 982 WX ion-exchange membrane was
used. The electrolysis voltage was 2.11 V. Into the anode chamber
was metered 0.8 kg/h of a 25% by weight NaCl-containing solution.
The sodium chloride concentration of the solution taken off from
the anode chamber was 19.8% by weight of NaCl. To the NaCl solution
taken off from the anode chamber were added 0.180 kg/h of 18.0% by
weight reaction waste water and 0.0557 kg/h of solid sodium
chloride. The solution was subsequently fed back into the anode
chamber. The transport of water through the membrane was 4.9 mol of
water per mol of sodium.
[0186] On the cathode side, a sodium hydroxide solution was
circulated by pumping at a mass flow rate of 1.107 kg/h. The
concentration of the sodium hydroxide solution fed into the cathode
side was 30.0% by weight of NaOH, and the sodium hydroxide solution
taken off from the cathode side had a concentration of 31.0% by
weight of NaOH. Of the 31.0% by weight hydroxide solution, 0.192
kg/h was taken off from the volume stream, and the remainder was
replenished with 0.0345 kg/h of water and recirculated back to the
cathode element. The fraction of reacted sodium chloride from the
polycarbonate reaction waste water was 36.9%.
Comparative Example 4
[0187] a) Production and Workup of the Polycarbonate
[0188] A reaction waste water from the polycarbonate production,
obtained as described in example 3a), is not combined with the wash
phases and is freed from solvent residues and catalyst by stripping
with steam. After neutralization with hydrochloric acid and
treatment with activated carbon, the reaction waste water contains
10.0% by weight NaCl and <2 ppm of free BPA and phenols,
measured by UV spectroscopy of the aqueous phase at 294 nm, e.g. in
a Perkin-Elmer spectrometer. The reaction waste water is used
directly in the electrolysis without concentration.
[0189] b) Electrochemical Oxidation of the Sodium Chloride Solution
(Reaction Waste Water)
[0190] The electrolysis was carried out by way of example in a
laboratory electrolysis cell having an anode surface area of
0.01m.sup.2. The current density was 4 kA/m.sup.2, temperature at
the outlet on the cathode side 88.degree. C., temperature at the
outlet on the anode side 89.degree. C. An electrolysis cell having
standard anode and cathode coatings from DENORA, Germany was used.
A DuPont Nafion.RTM. 982 20 WX ion-exchange membrane was used. The
electrolysis voltage was 3.02 V. A sodium chloride-containing
solution was circulated through the anode chamber by pumping at a
mass flow rate of 1.0 kg/h. The concentration of the solution fed
to the anode chamber was 25% by weight of NaCl. From the anode
chamber, a 20% by weight NaCl solution could be taken off. To the
NaCl solution taken off from the anode chamber was added 0.125 kg/h
of 10.0% by weight reaction waste water from the polycarbonate
production and 0.076 kg/h of solid sodium chloride. The solution
was subsequently fed back to the anode chamber. The transport of
water through the membrane was 3.5 mol of water per mol of sodium.
Of the NaCl solution arriving from the cell, 1% was discarded,
equivalent to 0.008 kg/h of a 20.0% by weight NaCl-containing
solution.
[0191] On the cathode side, a sodium hydroxide solution was
circulated at a mass flow rate of 1.107 kg/h. The concentration of
the sodium hydroxide solution fed into the cathode side was 30.0%
by weight of NaOH, and the sodium hydroxide solution taken off from
the cathode side had a concentration of 31.9% by weight of NaOH. Of
the 31.9% by weight hydroxide solution, 0.188 kg/h was taken off
from the volume stream, and the remainder was replenished with
0.0664 kg/h of water and recirculated back to the cathode
element.
[0192] Only 14.0% of the reacted sodium chloride originates from
the polycarbonate reaction waste water.
Comparative Example 5
[0193] a) Production and Workup of the Polycarbonate
[0194] The reaction waste water of comparative example 4 was
used.
[0195] b) Electrochemical Oxidation of the Sodium Chloride Solution
(Reaction Waste Water) Using a Gas-Diffusion Electrode
[0196] Since no hydrogen is required for the production of
polycarbonate, the formation of hydrogen in the electrolysis can be
omitted. The electrolysis was therefore operated using
gas-diffusion electrodes. The current density was 4 kA/m.sup.2,
temperature at the outlet on the cathode side 88.degree. C.,
temperature at the outlet on the anode side 89.degree. C. An
electrolysis cell having a standard anode coating from DENORA,
Germany, was used. A DuPont Nafion 982 WX ion-exchange membrane was
used. The electrolysis voltage was 2.11 V. A 25.0% by weight NaCl
solution was fed into the anode chamber at 0.65 kg/h, and the
solution taken off from the anode chamber contained 18% by weight
NaCl. To the NaCl solution taken off from the anode chamber was
added 0.163 kg/h of 10.0% by weight reaction waste water and 0.0715
kg/h of solid sodium chloride. The solution was subsequently fed
back to the anode chamber. The transport of water through the
membrane was 4.9 mol of water per mol of sodium.
[0197] On the cathode side, a sodium hydroxide solution was
circulated by pumping at a mass flow rate of 1.107 kg/h. The
concentration of the sodium hydroxide solution fed into the cathode
side was 30.0% by weight of NaOH, and the sodium hydroxide solution
taken off from the cathode side had a concentration of 31.0% by
weight of NaOH. Of the 31.0% by weight hydroxide solution, 0.192
kg/h was taken off from the volume stream, and the remainder was
replenished with 0.0345 kg/h of water and recirculated back to the
cathode element.
[0198] The fraction of reacted sodium chloride from the
polycarbonate reaction waste water was 18.6%.
[0199] The examples show that a significantly higher recycling rate
of sodium chloride can be achieved in the waste water solutions of
the polycarbonate production process in the electrolysis after
concentration by osmotic membrane distillation, wherein the water
taken up by the alkali metal hydroxide solution can be saved in the
production of the alkali metal hydroxide solution in the
polycarbonate production step.
* * * * *